The mill’s waste management system works in co-operation with UPM Paper ENA’s own employees and subcontractors. The waste collection system in the mill site consists of tip-ping skips and demountable waste container transportation. Despite of the scrap metal con-tainers that are owned by Kuusakoski Oy, all the skips and concon-tainers are owned by UPM Paper ENA Oy. Tipping skips are located around the mill site for source separation of the wastes. Common fractions that are collected at the site are factory waste, recyclable plastics and fibers, combustible material, domestic waste, metals and WEEE. Skips are color coded
and labeled for each fraction. The instruction labels explain what can be placed in the tipping skip. (Ojala 2016, 6-7.) A tipping skip and a demountable waste container are shown in the figure 13. There are also 140 liters (l) and 240 l wastebaskets in some locations where it is seen more suitable because of use of space. Wastebaskets are emptied to the tipping skips or directly to the demountable containers by employees.
Figure 13. Tipping skip (left side) for source separation and demountable container (right side) for waste transportation (Langtons 2016; DJE 2016)
Tipping skips are emptied to demountable waste containers by forklifts. The emptying is handled together by mill workers and a logistic company Järvelän Siirtokuljetus Oy. There are around 110 tipping skips at the factory site for source separation, of which 85 is emptied by UPM Paper ENA’s own employees and 25 by Järvelän Siirtokuljetus Oy. Transportation distance from tipping skips to demountable containers at the factory site varies between 100 and 300 meters.
Demountable containers are used for waste transportations. In the mill area there are in total around 30 actively used demountable waste containers. Demountable container traffic can be divided into external and internal transportations. Internal container transportation is ar-ranged by another local logistic company P. Peltomaa Tmi. Internal transportation contains of combustible material transportations to the biopower plant, packaging material transpor-tations to the loading station and some bottom ash and sand transportranspor-tations. External waste transportation consists of transporting wastes that can’t be handled at the site. This means landfill transportations and recyclable waste transportations to external partners. P. Peltomaa manages all the logistics to industrial waste landfill to Suiklansuo and to domestic waste
landfill to Hevossuo. Recyclable material container transportations and hazardous waste transportations for further processing are handled by the recipients.
All waste fractions produced and collected at the mill site are shown in the table 5. Some of the fractions are called differently at the site than generally. Therefore, there are examples what each fraction contains according to the recycling instructions. There is also a column where it is explained who is in responsible for the transportation, where the waste fractions are transported and for what purposes. Later these same names of the waste fractions are used in the study. Waste flows and processes are presented in the text more precisely after the table.
Table 5. Collected waste fractions, contents and current transportation (Ojala 2016, 22) Waste fraction Contents Transportation and location Combustible
material
-Dirty paper and cardboard -Felts and screens in pieces -Pieces of wood
-Plastics (Excluding PVC) -Styrofoam
-Ropes and rubber belts
Transported to energy recovery to Rauman Biovoima’s biopower plant by P. Peltomaa Tmi.
Factory waste
Transported to industrial waste landfill to Sui-klansuo for waste disposal by P. Peltomaa Tmi.
Domestic waste
Transported to municipal waste landfill to He-vossuo by P. Peltomaa Tmi. Wastes are trans-ported from there to energy recovery to Vaasa by the City of Rauma.
Metal scrap -Black metal scrap -Stainless steel
Transported by the city of Rauma to digestion plant of Biolinja Oy for biogas production.
Recyclable fibers -Paper roll sockets -Packaging card board -Paper roll wrappings
Transported to packaging material recycling sta-tion by P. Peltomaa Tmi. Paperinkeräys Oy empties the containers later for material recy-cling. sta-tion by P. Peltomaa Tmi. Paperinkeräys Oy empties the containers later for material recy-cling.
Hazardous waste -Oils and oil filters -Process chemicals -Fluorescents and batteries
Transported to the central warehouse by factory workers to a locked storage room. Ekokem Oy empties the storage room when necessary.
Ash -Bottom ash
-Fly ash
Transported to Suiklansuo’s construction pro-ject by Rantanen Osku Tmi and P. Peltomaa Tmi.
Kaolin sludge -Kaolin sludge Circulated back to the process. Also utilized as a raw material in the brick industry.
Sludge from the
Combustible material collected at the mill site and from offices is used for energy production.
Energy recovery takes place in the biopower plant, which is owned by Pohjolan Voima Oy.
The company operates at the same site with the paper production. Combustible material col-lected from the mill site consists of pieces of felts and screens, styrofoam, oily fibers, dirty papers, cardboard and belts (Ojala 2016, 24). Collected paper from the offices is incinerated at the biopower plant instead of recycling due to confidential reasons. (Ojala 2016, 15). Ex-cess paper from the production is re-pulped and used in the paper production as a raw mate-rial. Combustible materials are collected also externally from private and public sector. In the beginning of 2016 the city of Rauma started collecting waste for energy recovery. Col-lected material contains of combustible non-hazardous waste fractions like cardboards, plas-tics, stryrofoam and textiles (Rauma 2016a; Rauma 2016b). Collected waste for energy pro-duction from mill site and externally goes through mechanical treatment process which in-cludes crushing and screening before it is utilized as a recovered fuel (REF) at the incinera-tion plant.
The biopower plant is combined energy and heat production plant. The power plant consists of two actively used boilers: circulating fluidized bed boiler (180MW) and a bubbling fluid-ized bed boiler (120MW). Besides, there is a smaller back up boiler, which is run by heavy fuel oil. (52/2011/ESAVI.) In the year 2014 energy production at the biopowerplant was 474,7 GWh (Energiateollisuus 2014). The fuel used in the biopower plant consists of biofu-els, peat and REF. Biofubiofu-els, which covers the largest share of the fubiofu-els, consist of forest fubiofu-els, wood residues from factory site and sludge from the waste water treatment plant. In addition, there is a permission to incinerate wooden railroad sleepers. Recyclable oil from the paper factory is used to lubricate the conveyor lines. Fuel distribution at the biopower plant in 2014 is shown in the figure 14. Non-renewable energy sources that are used in the ramp-up situa-tions consisted of coal and heavy fuel oil.
Figure 14. Fuels used in heat production at Rauman Biovoima’s biopower plant in the year 2014 (Ener-giateollisuus 2014)
Landfilled waste consists of waste fractions which doesn’t have yet a utilization purpose or which can’t be utilized by legal means at the mill. At the mill, these fractions are called factory waste and domestic waste. Factory waste represents a mixed waste fraction which is collected at the production sites and it covers clearly the biggest share of landfilled wastes.
The fraction is transported to industrial waste landfill to Suiklansuo, owned by UPM paper ENA. Factory waste consists of PVC -plastics, carbon fiber scrapers, abrasive discs, ceram-ics and mineral wool. Also a lot of combustible and recyclable materials end up to the landfill due to deficiencies in source separation. (Ojala 2016, 10-11; 15-17; 26.) A small share of landfilled waste is covered by construction waste. Construction waste collection is mostly project related action.
Domestic waste, which is at the moment transported to the Hevossuo’s municipal landfill, consists basically of combustible material such as paper cups, paper plates, food wrappings and napkins. The waste fraction is comparable to municipal solid waste. Domestic waste is still collected from controlling rooms, break rooms and offices. From Hevossuo the wastes
81 % 15 %
3 % 1 %
Biofuels REF Peat Non-renewable energy sources
are transported to Vaasa to waste incineration plant owned by West Energy. The transporta-tion is handled by the city of Rauma with other collected municipal waste (Rauma 2016; Yle 2014). Current operation model at the mill has been already noted to be outdated. The inten-tion is to remove the domestic waste baskets, change them to the combustible material bas-kets and incinerate the wastes at the biopower plant. To assure that there wouldn’t end up any harmful residues to combustion glass and metals are collected separately at the break rooms. This practice was already partly adapted during the study.
Bio waste collection started at the factory site in the summer 2016. It is mainly collected from the factory canteen, but also three office floors have baskets to separate bio waste as a pilot experiment. Bio waste is gathered into a deep collection container from the offices and the canteen by cleaning stuff. Collected bio waste is transported to biogas production to Uusimaa to Biolinja Oy. Transportation to the bio gas plant is handled by the city of Rauma.
Currently left overs, coffee grounds and fruit peelings produced at the mill site are directed to incineration. According to the conversation the volume of produced biowaste in the pro-duction site is so small that the separation would cause unreasonable amount of work com-pared to the benefits. It will be discussed later if the bio waste separation should be started on a larger scale at the mill.
Collected recyclables such as metals and packaging materials and also bio waste are handled by external partners. Kuusakoski Oy is responsible for recovering and transporting metal scrap and WEEE. Collected metal scrap at the mill site is mainly a mixture of different metal qualities and sold as a black scrap metal to Kuusakoski. There are also few containers for stainless steel but the separation of black scrap metal and stainless steel is more project re-lated action. In addition, there is an aluminum separation at the biopower plant. Collected scrap metal is used as a secondary raw material in a metal production by Kuusakoski Oy.
Produced metal scrap is strongly related to demolition projects at the mill site and the annual amount can vary a lot. Separated packaging materials, plastics and recyclable fibers, are recovered by Paperinkeräys Oy. Paperinkeräys Oy have invested to a packaging material recycling station, which is located at the mill site. The recycling station consists of sheltered containers for recycled fiber and plastics. P. Peltomaa transports the material from the pro-duction site to the station from where Paperinkeräys Oy takes care of the recyclable fractions.
Ekokem Oy handles hazardous wastes produced at the mill site. The company is specialized in hazardous waste material treatment. Their technique generally bases on a high tempera-ture incineration, which allows them to burn materials on a wider scope than a normal waste incineration or co-incineration plant. (Ekokem 2016.) Hazardous waste collected from Rauma’s paper mill consists mainly of oily filters, batteries, process chemicals, fluorescent lamps and oils. Mill’s own employees centrally collect these fractions to a locked warehouse where Ekokem Oy collects them when necessary. The hazardous waste production varies a lot annually. (Ojala 2016, 15-16.) On the average the warehouse is emptied two or three times per year.
In addition to regular waste fractions, which are collected at the mill site, there are production related waste fractions. The nature of these residues is different because of the large annual volumes. These fractions at Rauma’s mill site are for example: fly and bottom ash, wood chips, barks, kaolin sludge and sludge from the waste water treatment plant. At the moment, the situation in Rauma is very good due to a large landscaping project. UPM Paper ENA’s mill in Rauma has received an environmental permit to fill Sampaanala’s gulf with certain waste materials. The Sampaanala’s gulf is an elongated inner gulf of the Bothnian Sea and located to vicinity of the paper mill. In addition to the paper mill, there are a pulp mill, biopower plant and wastewater treatment plant located around the gulf. Objective in the pro-ject is to use as much materials that would be otherwise classified as a waste from the local industry as possible to replace natural resources as a filling material. Waste flows such as demolition material, fly ash, bottom ash, sludge from the waste water treatment plant, green liquor sludge, kaolin sludge and tire crumbs are allowed to use as a filling and stabilizing material. (21/2010/ESAVI) Because of the project Rauma’s mill site have reached the recy-cling rate of 100 % for ash and kaolin sludge.
After the project at the gulf of Samaanala started in 2012, all of the ash and kaolin sludge produced at UPM Paper ENA’s mill site have been located to the gulf and also reserves stored to Suiklansuo’s landfill have been transported to the project. In addition, a large amount of rocks, cement and bricks from demolition sites have been used in the project. The filled area is meant to use after the project as a storage field for wood. The permit for the
project came in to effect at 28th of March in 2011 and it allows the project continue ten years after its beginning. It is estimated that the project will still last 5-7 years. The project won an award from a Finnish Geotechnical Association from an advanced and effective excess ma-terial utilization in 2013. (21/2010/ESAVI; UPM 2016d.)
The waste water treatment plant is managed by UPM Paper ENA Oy. It processes both in-dustrial and municipal waste waters. The inin-dustrial waste waters are directed to the primary clarifier and the municipal waste water straight to the aeration pool. Processed sludge con-tains high percentage of clay and other rock materials from the paper industry. Mixed sludge is incinerated at the incineration plant, but the environmental permit also allows using it in the Sampaanala’s construction project. The mixed sludge is defined as a slightly biodegrada-ble but it is not seen as a probiodegrada-blem in the construction work. (21/2010/ESAVI.) The calorific value of the sludge is relatively low or in some cases even negative depending on the dry-content of the sludge.
Kaolin is used in a pigmentation material in paper production. For the most part kaolin res-idue is recycled back to the process. (21/2010/ESAVI.) Remaining kaolin sludge were earlier disposed into a kaolin pool to Suiklansuo, but authorities prohibited this action in 2012 and ordered to rebuild the base structure of the pool. The pool was not completely renovated for the disposal and therefore it can’t be used for the kaolin sludge disposal at the moment. A ramp for unloading was built in 2014, but the ground works weren’t seen necessary to start since the sludge is allowed to use in the gulf filling project. Currently the kaolin sludge is circulated back into the process. Kaolin sludge has also been used as a raw material in brick industry, but the problem is a low dry-matter content, which increases the transportation costs. The year 2014 was the best, when 1819,72 t of kaolin was transported to Kemiö for Tiileri Oy. This included the kaolin sludge transportations from the intermediate storage from Suiklansuo. The sludge was mainly collected from Suiklansuo where the stored sludge was already thickened and therefore easier to transport. Main waste flows at the site are summarized in a waste diagram in figure 15. In the figure, collected wastes at the factory site are divided into three categories: recycling, energy recovery and waste disposal.
Figure 15. Waste diagram from Rauma's factory site (Ojala 2016, 4)
All waste fractions, except the waste water sludge and wood chips, are weighted at the weighting station which is located at the factory area. Weighting service is out sourced to Mitta-Asema, which is owned by Metsä Fibre Oy. Beside the paper mill, the weighting sta-tion is also used by the pulp mill owned by Metsä Fibre Oy and external parties who transport material in and out from the factory site. Driver informs at the scale the transported waste fraction, its origin and where it is going to be located. The information is downloaded to a Rapu-database where the waste amounts are reported regularly. The information is used to report waste amounts and to track the waste generation.
Each waste container is also coded according to the location which enables to track the origin of the produced wastes. The intention of the system is to enable to develop waste manage-ment and to follow the waste managemanage-ment costs unit specifically. The tracking system bases on demountable container coding system. Besides that, all waste fractions are coded due to the European Waste Catalogue (EWC) coding system. In addition to EWC codes, local ad-ditional codes are used to individualize the fractions more accurately.